Apparatus for assembly of connector plugs



March 31, 1942. w. P. HERMAN APPARATUS FOR ASSEMBLY OF CONNECTOR PLUGS S'Sheets-Sheet 1 Filed May 51, 1959 March 31, 1942.

w. P HERMAN APPARATUS FOR ASSEMBLY OF CONNECTOR PLUGS Filed May 31, 1959 5 Sheets-Sheet 2 INVENTOR Wm WM fix? 4TTORNEY March 31; 1942. w. P. HERMAN APPARATUS FOR ASSEMBLY OF CONNECTOR PLUGS 5 Sheets-Sheet 3 Filed May 51, 1939 M ATTORNEY I March 31, 1942. w. P. HERMAN APPARATUS FOR ASSEMBLY OF CONNECTOR P LUGS Filed May 31, 1959 5 Sheets-Sheet 4 INVENTOR %\TTORN EY March 31, 1942. w. P. HERMAN v 6 APPARATUS FOR ASSEMBLY OF CONNECTOR PLUGS Filed May 51,- 1939 5 Sheets-Sheet 5' I Ma . INVENTOR ATTORNEY Patented Mar. 31, 1942 U TED STATES PATENT? eFFIC-E APPARATUS FOR ASSEMBLY OF CONNECTOR PLUGS William P. Herman, Providence, R. I. Application May 31, 1939, Serial No. 276,625

4 Claims.

My present invention relates to the manufacture of electrical connector plugs, and has par-- ticular reference to an apparatus for assembling contact prongs in the lug body.

The present application constitutes a continuation in part of my copending application Serial No. 99,848, entitled Connectorplug assembly apparatus, filed September 8, 1936, now Patent No. 2,198,966, dated April 30, 1940.

It is the principal object of the present invention to provide a simple and readily operated apparatus for assembling contact prongs and plug bodies made of resilient material.

It is a further object of my invention to provide structures for holding a plug body and for drawing the prongs therethrough into locking engagement therewith.

It is an additional object of my invention to provide an apparatus for inserting prongs having laterally displaced portions and resilient plug bodies having correspondingly shaped recesses whereby the prongs are securely locked in the body. F

A further object of my invention is to provide improved means for distending the plug body during the passage-of the contact prong and for disengaging the plug body from the machine after assembly. 1

Another object of my invention is to provide means for testing the contact plug while it is being assembled.

A further object of my invention is to provide a simple apparatus which can :be readily adjusted for assembling eitherordinary contact plugs or multiple current taps.

Another objector my invention is toprovide an improved valve mechanism for operating the machine of the present invention.

With the above and other objects and advantageous features in view, my invention consist of a novel arrangement of parts-more fully disclosed in the detailed descriptionfol-lowing, in conjunction with the accompanying drawings, and more specifically defined --in the claims appended thereto.

In the drawings: a r

Fig. 1 is a plan view of an apparatus embodying my invention;

:Fig. 2 is a sideelevationthereof;

Fig. 2a is a perspective view ofthe angle plate;

Fig. 3 isa plan view of the novel" apparatus, parts being removed;

Fig. 4 is a vertical section along line 4-4 on Fig. 1;

Fig. 5 is a section taken along line 5-5 on Fig. 3;

Fig. Fig. 4;

Fig. 7 is a perspective view of the operating valve mechanism;

Fig. 8 is a section taken along line 8-8 on Fig. '7;

" Fig. 9 'is a section taken along line 9-9 on Fig. 8;

Fig. 10 is a section taken along line Ill-I0 on Fi Fig. 11 is a perspective view of the air baffle;

Fig. 12 is a section taken along line I2-I2 on Fig. 8;

F Figs. 13, 14 and 15 are diagrammatic views showing the assembly steps;

Fig. 16 is a diagrammatic view showing the electrical testing hookup;

Fig. 1'7 is a detailed perspective view showing the construction of the testing mechanism;

Fig. 18 is a perspective view of the cover for thefinder carriage;

Fig. 19 is a plan view of a modified form of my novel apparatus for assembling multiple current tap plugs;

Fig. 20 is a side elevation thereof;

Fig. '21 isan end view of a vertical slot contact holder; and

Fig. 22 is an elevation of the trigger ram.

It has been found desirable to provide an apparatus for facilitating the assembly of contact plug bases with the prongs and electrical cord connections by pulling the prongs into the base; the prongs having laterally displaced portions forming locking shoulders, and the bases having corresponding recesses whereby the displaced portions securely lock the prongs in the bases against-removal. In addition to the conventional two-prong connector plug, the modified form of my invention is designed to assemble a multiple current tap plug having four contacts intersecting at right angles to each other. The present apparatus is designed to be highly adjustable for precision work and is further designed to eliminate unnecessary parts and reduce the number of parts on the operative structure.

As'd'escribed in my copending application, Serial No. 99,848, a plug base is set into the apparatus, two pull arms are then passed through the base recesses while the base neck is distended, the prong assembly is then secured to the pull arms, and the .pull arms are then withdrawn through the plug base to insert the prongs into 6 is a section taken along line 66 on the base recesses, thus completing the assembly.

Referring to the drawings, my improved apparatus 36 includes a lower casing 3| Which houses the actuating mechanism, and on which the assembly parts are mounted. A plug base is seated in a retaining nest 32 mounted on the casing and shaped to receive the base; two resilient pull arms 33 having hooked ends 34 are mounted in a carriage 35. The carriage 35 comprises a block 36 having laterally disposed grooves 31 in which the pull arms are recessed. The pull arms are held in the grooves 31 by an upper plate 38 which is bolted to the block 36, as

by bolts 39. To adjust the extension of the pull arms, their inner ends are turned at right angles, at 40, and the inner ends abut the adjustment plate 4| which is adjustable through the slots 42 and bolts 43 extending into the blocks 36. The carriage 35 is provided with side rails 44 to slide in aligned grooves 45 in the casing top. The carriage also carries, on either side, cam bars 46 having their forward outer corners cut off, a at 41, for actuating the cam. As can be seen in Figs. 3 and 4, the block 36 carries a cam tongue 48 beneath it which is tapered, as at 49, adjacent its forward end and terminates in a narrow bar portion 56.

Now referring to Figs. 1 and 2, the lower casing 3| is provided adjacent its central portion with extension block disposed on either upper side edge of the lower plate and preferably integral therewith. The upper rear surface of the extension portions 5| carry a cam plate 52 on which is loosely pivoted, as at 53, and i provided with an inner angular cam edge 54 which is adapted to extend in the path of the cam bars 46 on the side of the carriage. An L-shaped cam element 55 is loosely pivoted at 56 On the forward portion of the extension block 5|, with one arm, 51, bearing against the outer edge of the cam plate 52, and the other arm, 58, being connected at its other end by a coil spring 59 to the pivot 53. The coil spring 59 therefore continually urges the L- shaped cam element 55 backward, the arm 51 urging the cam plate 52 into the path of the cam bars 46 on the carriage.

Referring now to forward portion of the machine, and more particularly to Figs. 1 to 6 inclusive, the upper surface of the base 3| is pro- 0 vided with a transverse groove 66. Rectangular blocks 6| and 62 are positioned to slide above the groove with integral depending portions63 extending into the groove at their outerend. The blocks 6| and 62 are urged toward each other by a spring 64 positioned in the groove 60 and having each end attached to an extension portion 63. Each block 6| and 62 is also provided with a transverse openin 66, and the base 3| is provided with integral laterally extending portions 61 having openings 68 adapted to register with the openings 66 when the block 6| and 62 are pushedapart. Spreaders 69 are pivotally mounted on blocks 6| and 62, the inner ends of the spreaders being formed as hooks and the outer ends being pivotally engaged with adjustable rods 1| which have their other ends pivoted, as at 12, to the arm 58 of the cam 55. The tongue 48 is guided in its forward movement between guide block 13 set in the base and integral therewith.

Each side of the base is equipped with a rod 14 having its front ends slidable in the openings 68 of the block 61 and having its rear end bent upwardly and over the base, as at 16, into the path of the cam bars 46. The rods 14 are held slidably in position by the journal block 11 and the central portion of the rod, 18, is bent downwardly to just clear the depending portion 5| of the side extension.

A pull arm guide 19, see Figs. 1, 2 and 6, is positioned in front of the retaining block, and has a tapered front portion 80 which extends between the pull arms in their forward movement and gradually pushes them apart, and has side transverse grooves 8| in which the pull arms ride in their forward motion. The top of the guide 19 is surmounted by a guide plate 82 which widens at its front end 83 and is provided with a depending flange 84 under which the pull arms slide and which retain the pull arms in the grooves 8| during the pulling movement and while the plug base is being disconnected from the pull arms.

To facilitate operation the machine is preferably tilted forwardly towards the operator at an angle of approximately 30 by mounting it on a pair of angle supports 84, see Fig. 2a, which may be clamped to the bottom of the base.

The operation of the assembling parts may now be explained. Referring to Figs. 1 to 6 inclusive and the diagrammatic views l3, l4 and 5, a plug husk 86 is seated in the retaining nest 32, wher it is held against displacement, and the carriage 36 is moved to the left, the pull arms 33 entering into the groove 8| in the pull arm guide 19 and being guided thereby through the husk slots. As the carriage moves to the left, the ends 16 of the rods 14 are released and pulled forwardly by springs 85 until the front ends 15 bear against the blocks 6| and 62. The tongue 48, guided between the guide blocks 13, moves forwardly until the front end passes between the blocks 6| and 62 and the tapered edges 49 engage the cam edges on the blocks 6| and 62 and force them apart against the action of the spring 64. The blocks 6| and 62 continue to move outwardly until the openings 66 are aligned with openings 68 in the extension block 61 and they are then looked in this position by the end 15 of the rod 14 which is pushed forwardly by the spring 85. At the same time, the

cam bars 46 on the carriage engage the angular cams 52 and push them against the arms 51 of the L-shaped cams and turn them against the action of the spring 59. This action is transmitted through the arms 58, adjustable bars 1| to the pivoted spreaders 69 which are then swung to the dotted line position shown in Fig. 1, and thus enter the cable neck opening of the husk and spread it. The initial position of the parts is shown in Fig. 13, and the second position is shown in Fig. 14. The prong assembly is now attached to the hooked ends 34 of the pull arm and the carriage is moved to the right, thus retracting the pull arm and drawing the prongs through the plug husk slots. As the retraction continues, the parts are held in distended position, as shown in Fig. 14, b the locking action of the rods 14. When the carriage has reached its extreme right position, it has released pressure of the cam bars against the angle cams 52 and L-cams 55, and bump against the ends 16 on the rods 14 withdrawing them from the aligned openings 66. Immediately, all tension springs are brought into play,'and the blocks 6| and 62 pull towards each other while the L- shaped cam 55 swings about its pivot causing the spreaders 69 to return to normal position as shown in Fig. 15. Inasmuch as the pull arms 33 are adjusted at an angle they will tend to spring toward each other after clearing the end on the pull arm guide I9 and to disengage the hooked ends 34 from the contact blades. However, they may not completely disengage and this can be completed by the pulling of the electrical cord upwardly and forwardly, thus also pulling the husk 86 from the retaining nest 32. The plate 82, having the flange 84 hearing down upon the end of the pull arms 33, prevents their being forced from their position in the grooves 8I.

The above-described operation is independent of any specific operating force; electric power, hydraulic pressure, mechanical or any other type of operating means may be used. It is preferred, however, to utilize compressed air as the operating medium, and the structure shown is therefore so illustrated. As described in my copending applioation Serial No..99,848, the carriage is operated by a piston 90 in a bore 9| having pipe connections 92 and 93 at each end for alternately transmitting compressed air under pressure.

Whil any type of control mechanism may be used, I prefer to use the foot pedal type shown in Figs. '7 to 12 inclusive, which leaves the operators hands free. The control valve 94, comprising a suitable casing 95 which may be bolted to the floor and is operated by a pedal 96 journalled to the control shaft 91 and held in inoperative position by the coil spring 98. The compressed air enters the casing 95 through the inlet 99 and is directed through outlets I and IOI to pipes 92 and 93 connecting with the assembly machine base. The forward end of the casing 95 is provided with an outlet I02 for the exhaust. The casing 95 is provided with a pressure chamber I03 to which the inlet 99 communicates. Referring to Fig. 9, the upper portion of on wall of the chamber I03 is provided with three openings I04, I05 and I06 respectively, the

central opening I05 communicating with the ex-,

haust port I92 and the openings I04 and I06 communicating with ports I00 and MI respectively. The air baflle I0! is constructed as shown in Fig. 11 with a central journal opening I08 having a key slot I09 into which the operating shaft 91 is keyed, as at I'I0. Integrally formed with the air baffle I0! is a rearwardly extending shaft I I I which is slidably journalled in the rear of the casing to permit slight lateral movement of the air baflle. The air bafile I0! is adapted to fit tightly within the pressure chamber I03 so that the pressure of the fluid entering the inlet 99 will force it against the wall I I2. This action is supplemented by the spring IIIa. The upper portion of the air baffle I01 is provided with an enclosedchamber portion II3 having the front end open and which is large enough to just cover two of the openings I04, I05 or I06.

The operation of the valve is asfollows: As can be seen in Fig. 12, when the pedal is in the position shown in Fig. 7, the air bafile I0? is angularly disposed so that the chamber Il3 covers openings I05 and I09 and uncovers opening I04. Th pressure of the compressed 'air entering the port 99 into the pressure chamber I03 goes through the opening I04, outlet I0 I, into the pipe 93 and keeps the carriage of the machine to the right, the cylinder to the right of the piston 90 communicating through the pipe 92, opening I00 and port I06 through the chamber H3 and port I05 with the outlet port I02. When it is desired to mov the carriage of the machine to the left, the pedal 96 ispushed so that the shaft 91 will force the air bafile to turn into the position shown in dotted lines in Fig. 12, covering ports .104 and I05 and exposing port I06.

The pressure from the pressure, chamber I03 will then enter the port I06, outlet I00, pipe 92,

and into the base of the assembly machine and force th 'carriage to the left. At the same time, the air in the cylinder to the left of the piston 90' will be pushed outwardly through the pipe 93, port IOI, port I04, through the chamber II3, out of port I05, and out of the exhaust I02.

It is obvious, that where hydraulic pressure is used, it may be necessary to attach the exhaust port I02 through pipesback to the oil sump.

As can be readily understood from the machine heretofore described, the assembly of the cord, plug and blade is done at a rapid rate of speed, and since each plug requires two cord connections and two blades, it is apparent that the blade and cord, which are preassembled, must be turned out at a rapid rate. Various methods of assembly are used, such as soldering, spot welding, and clamping. Whatever the method, it must be fast and accurate and the connection must be strong. However, occasionally the connection may be so weakened that when the pull arms in themachine pull the blade into the plug husk one of theelectrical cord connections may be disconnected from the blade. If this happens within the plug husk, the finished plug is obviously defective, and there is no way of checking this without actual test. To avoid the necessity of separate testing, I have devised the testing mechanism shown in Figs.16,'17 and 18 which may be readily applied to the heretofore described machine. I r

The electrical cord connections usually come in bundles with the bare ends hanging downwardly. It is therefore merely necessary, as in Fig. '16, to place the ends I20 into a box of steel wool I2I toinsure electrical contact. A brine tank or othe'rco'nducting means may also be used for this purpose. The pull arm guide I22 is preferably made of tough fibre or other dielectric materials and the pull arms I23 are encased in dielectric coverings I24at the point where they are imbedded in the grooves in the block I25; The pull arms are held in the block by means of the plate I26 which is separated from the block I25 and the pull arms' by a sheet'of fibre or other insulating material I21. 'To the extreme the rear of the pull arms on their return stroke.

The contact pins I29 and I30 are connected by suitable wiring means to an electric bulb I3I and 6 to 12 volt transformer I32. When the machine is assembling a plug and the carriage moves rearwardly so that it reaches the point where the plug is completely assembled, the back ends of the pull arms contact the pins I29 and I30. This completes an electrical circuit through the cord lead wire, contact pin I30, the pull arm, through the plug husk, through the cord end I20, into the steel wool I2I, back through the other pull arm, through the contact pin I29, and lights the bulb I3I. This tells the operator that the connection between the cord lead wire and the contact blade in the plug husk is complete.

the husk which is being removed from the machine as inoperative.

- This gives a positive, accurate and rapid check of each plug husk as it is being completed in the machine and saves the time of additional checking later on.

When it is desired to assemble cube taps or multiple current tap plugs, the augmented machine, shown in Figs. 19, 20, 21 and 22, may be used. This machine may be made by attaching certain additional parts to the machine heretofore described, or by constructing a new machine.

The multiple current tap plug requires the insertion of two pairs of contact blades in the plug husk. One of the pairs may be pulled through by the method heretofore described and the other pair, disposed at right angles to the first pair, may be pushed into the husk.

Referring to Figs. 19' and 20, the machine base I35 is similar to the one heretofore described and is operable in the identical manner. It is provided with a carriage I36, the same cam movements I31, and the spreaders I38. sembling a multiple current tap plug to which there is no electrical cord connection, the spreaders I38 may be eliminated. The retaining nest I39 is provided with an annular seat I40 adapted to hold the plug husk and two upturned retaining prongs I4I which partially enter the vertical slots in the plug husk to hold the husk in place and to act as a stop when the vertical contacts are pushed into the husk. The horizontal blade and cord connection are assembled in the conventional manner heretofore described, the pivot studs I42 raising the operating mechanism to the level of the transverse openings. Mounted on the carriage I36 is a frame I43 in which is slidable an auxiliary carriage I44. Pivoted on the auxiliary carriage I44 is a vertical slot contact holder I45 having a hook I46 which is adapted to engage the bar I41 in its path, the bar I41 being held in place by the plate I48 fixed to the side of the base 135. The holder I45 is provided at one end with slots I46, one wall of the slots I45 being formed by a plate I41 which is held in place by a screw I48 with a spring action. Journalled on the outside of the frame I41 is an S-shaped bar I49 having one end I50 adapted to abut against a frame II attached to the base I35 adjacent the nest. The other end, I52, is attached to the vertical slot contact holder I45 to limit movement of the auxiliary carriage. The frame I43 is provided with a forwardly extending cam bar I53 and a rearwardly extending cam plate I54 adapted to engage a rocker arm I55 which is pivoted to the base I35 and is long enough to engage the end I50 of the S-shaped bar I49. The bar I49 is held in position to the left by a spring I56.

Pivoted on the frame I5I is an operating tr1gger I51 which is pivotally connected with a cam I58 which is adapted to swing in a vertical line over the nest.

In operation, a multiple current tap husk is placed into the nest I39 with the pins I4I entering into the vertical slots. Two contacts are placed into the vertical slot contact holder I45 and held therein by the spring action of the plate I41. The machine is now moved to the left and the pull arms and spreaders operate as heretofore described. The frame I43 moves to the left with the carriage and carries the auxiliary carriage with it. As the vertical slot contact holder I45 passes beneath the bar I41, the hook I46 engages the bar I41 and swings the holder I45 to avertical position. When the carriage has moved sufficiently so that the holder In as-' place and slide in its grooves.

I45 is in alignment with the vertical slots of the husk, the S-bar I49 abuts against the frame'l5l' and its other end I52 prevents further movement of the holder I45 and auxiliary carriage I44. Further movement of the carriage I36 causes the auxiliary carriage I44 to remain in Simultaneously with this further movement, the cam bar I53 engages the trigger I51 and the cam I58 swings downwardly and engages a ram I59 in the holder I45 forming the contacts out of the slots I46 and into the vertical slots in the husk until the pins I4I are reached.

As the carriage is returned to the right, the cam bar I53 releases the trigger I51 and returns the cam I58 to its original position. The spring I55 pulls the S-bar I49 and auxiliary carriage I44 to the left of the frame I43. Further movement, however, causes the bar I41 to hit the holder I45 and return it to its horizontal position. At the same time, the cam plate I54 engages the rocker arm I55, which in turn engages the end I50 of the S-bar I 49 and pulls the S-bar and auxiliary carriage to the right of the frame I43 against the action of the spring I56, so that the end of the holder I45 is exposed in position for landing. 1

The machine of my present invention is therefore an improved construction which provides the spreading of the spreaders with a cam bar which relieves the upper structure of parts-and relieves the stress of unnatural cam action. Furthermore, by the use of the present machine, a more precise movement of the pull arm is possible and a more direct action is obtained, giving longer life to the machine. The springs are direct and operate directly upon the cam instead of indirectly as in the previous machine of the present type.

Another great advantage of the present machine is the fact that the husk of the plug is held open during the entire assembly movement and the spreaders do not release the husk until the assembly is entirely completed and at the end of the backstroke of the assembly carriage. This prevents tearing of the husk.

By the use of the valve mechanism hereinabove described, it is possible for the operator to have both hands free and the electrical hookup provides a positive check of each plug while it is being assembled without loss of time and without the requirement of further testing.

The augmented machine permits the assembly of multiple current taps with the same ease and speed as the conventional contact plugs without radical changes in the original machine.

While I have disclosed certain specific constructional embodiments of my invention, it is obvious that desired changes in the shape and location of the parts and of the movement and sequence of the cam action may be made to suit different requirements, and that the principles of my invention may be applied to other articles and other types of similar machines, Without departing from the spiritand the scope of the invention as defined in the appended claims.

I claim:

1. In an apparatus .of the type described, a base, a nest on said base for holding a resilient plug husk having a passageway arrangement, a carriage reciprocatable on said base, a pair of spaced pull arms mounted on said carriage and reciprocatable through said husk passageways, a pair of aligned blocks slidably mounted in said base, a spring connecting said blocks and adapted to resilientlyurge said blocks in alignment towards each other, a cam tongue mounted in said carriage and adapted to separate said blocks during the movement of said carriage, pivotally mormted fingers on said blocks for distending the husk passageway during the initial movement of said carriage, and lock pins slidably mounted on said base and adapted to enter openings in said blocks when said blocks are in separated position for locking said fingers in distending position during the movement of said carriage.

2. In an apparatus of the type described, a base, a nest on said base for holding a resilient plug husk having a passageway arrangement, a carriage reciprocatable on said base, a pair of spaced pull arms mounted on said carriage and reciprocatable through said husk passageways, a guide block mounted on said base for guiding the pull arms during reciprocation, said block having means for retaining said pull arms in operative engagement therewith, a pair of aligned blocks slidably mounted in said base, a spring connecting said blocks and adapted to resiliently urge said blocks in alignment towards each other,

a cam tongue mounted in said carriage and adapted to separate said blocks during the movement of said carriage, pivotally mounted fingers on said blocks for distending the husk passageway during the initial movement of said carriage, and lock pins slidably mounted on said base and adapted to enter openings in said blocks when said blocks are in separated position for locking said fingers in distending position during the movement of said carriage.

3. In an apparatus of the type described, a base, a nest on said base for holding a resilient plug husk having a passageway arrangement, a carriage reciprocatable .on said base, a pair of spaced pull arms mounted on said carriage and reciprocatable through said husk passageways, a pair .of aligned blocks slidably mounted in said base, a spring connecting said blocks and adapted to resiliently urge said blocks in alignment towards each other, a cam tongue mounted in said carriage and adapted to separate said blocks during the movement of said carriage, pivotally mounted fingers on said blocks for distending the husk passageway during the initial movement of said carriage, and lock pins slidably mounted on said base and adapted to enter openings in said blocks when said blocks are in separated position for locking said fingers in distending position during the movement of said carriage, said lock pins having portions thereof in the path of return movement of said carriage whereby said pins are withdrawn from said openings to release said blocks on completion of the reciprocating movement of said carriage.

4. An apparatus comprising a base, a nest on said base adapted to receive a resilient contact plug husk having an opening, a carriage mounted for reciprocating movement on said base, pull arms carried by said carriage and movable through a husk positioned in said nest, said pull arms being dielectrically insulated from said carriage and having their free ends extending rearwardly from said carriage, means for distending the husk opening, means for reciprocating said carriage to cause said pull arms to pull a cord and blade assembly into said husk, a block mounted .on said carriage and having spaced electrical contact terminals in the path of movement of said carriage adapted to contact the free ends of said pull arms on the completion of the pulling action, and means for registering an electrical current through said contacting terminals, pull arms and the cord and blade assembly when said carriage has completed its reciprocating movement and said pull arms have pulled the cord and blade assembly into said husk.

WILLIAM P. HERMAN. 

